Core transfer process

ABSTRACT

A METHOD AND APPARATUS FOR TRANSFERRING A PACKAGE OF YARN SUPPORTED BY A RIGID IMPERFORATE TRANSFER CORE TO A FORAMINOUS, RESILIENT DYE CORE OF PREDETERMINED SMALLER DIAMTER COMPRISING, IN SEQUENCE, THE STEPS OF INSERTING THE RESLIENT CORE INTO THE TRANSFER CORE; AND, REMOVING THE TRANSFER CORE WHILE PREVENTING AXIAL MOVEMENT BETWEEN THE YARN PACKAGE AND RESILIENT CORE.

g- 1, 1 H. AGIRARD 3,681,007

- CORE TRANSFER PROCESS Filed Jan. 12, 1971 2 Sheets-Sheet l INVENTOR#[ABEFT A 5/2410 ATTORNEYS g- 1, 1972 I ,H. A. GIRARD 3,681,007

CORE TRANSFER PROCESS Filed Jan. 12. 1971 2 Sheets-Sheet 2 /a I 7 v f fla A F/G. 7

I NVENTOR fRBEE T 4- 6 /9420 ATTORNEYS United States Patent Office3,681,007 Patented Aug. 1, 1972 3,681,007 CORE TRANSFER PROCESS HerbertA. Girard, 1025 Woodland Drive, Gastonia, NC. 28052 Filed Jan. 12,1971,Ser. No. 105,920 Int. Cl. Bc 8/02 US. Cl. 8-155 7 Claims ABSTRACT OF THEDISCLOSURE A method and apparatus for transferring a package of yarnsupported by a rigid imperforate transfer core to a foraminous,resilient dye core of predetermined smaller diameter comprising, insequence, the steps of inserting the resilient core into the transfercore; and, removing the transfer core while preventing axial movementbetween the yarn package and resilient core.

BACKGROUND OF THE INVENTION The invention relates to the processing ofyarns and, in particular, to a method for replacing the rigid impervioustransfer core in a yarn package with a foraminous, resilient core.

A long standing problem in the textile industry involves treating yarnand, particularly, bulked, continuous filament, thermoplastic yarns suchas polyester, nylon or cellulose triacetate yarn, and spun yarns, suchas direct spun rayon having residual shrinkage of up to 20% when exposedto conditions of high humidity or immersion in aqueous bath, or turboacrylic yarn having high residual shrinkage by reason of unrelaxed heatsensitive fibers in the yarn. Such yarn is generally wound into packageform about a paper core such that the outer portion of the package is atsubstantially a desired bulk level and the inner portion of the packageis below such desired bulk level. As disclosed in US. Pat. No.3,425,110, the bulk level of the inner portion of the package may beincreased by simultaneously removing the package core while inserting arigid, metal perforate core of a predetermined smaller diameter than thepackage core. The inner portion of the highly stretchable yarn thencontracts (and gains bulk) about the perforate core.

Thereafter the package is axially compressed to obtain a more uniformdensity throughout and then the package is generally treated with aheated liquid often containing dye, to stabilize the entire package ofyarn at substantially the desired bulk level. This treatment is carriedout in a conventional package machine which circulates dye from outsideto inside of the yarn package and viceversa. Layers of yarn packages areloaded into the machine. The stabilized package is dried and generallyrewound onto a cone for further processing.

The core transfer process as set forth in the aboveidentified patent issubject to various defects. Owing to the fact that both the papertransfer tube and perforated dye tube simultaneously move through theyarn, one exiting, and one entering, it has been found necessary tosandwich a paper or knit sleeve or sock between the yarn and thetransfer tube, to serve as a bridge or shield during transfer. Withoutsuch sleeve it has been observed that some of the strands of yarn becometrapped between the ends of the transfer tube and the dye tube duringthe operation, thereby disturbing the continuity of the yarn. Thisprocedure requires extra tucking operations and is expensive and undulytime consuming. Also, there is a tendency of the yarn package to comeapart and unduly distort during the above core transfer process owing tothe pressure and movement of the entering perforated tube, with aconsequent increase in damaged yarn packages. Further, package dyeingmachines have been limited in the volume of yarn which can be loadedinto them by the rigidity of conventional dye cores, which cannot becompressed to permit addition of more dye cores.

During stabilizing treatment and storage rigid-core supported yarnpackages are subjected to yarn sagging. Sagging is produced by undulyrelaxed inner layers of yarn and by the spaced stacking of rigid coresupported yarn packages. Rigid core packages are separated from eachother by a spacer seal. Yarn can sag into the interstices between yarnpackages caused by such spacer seal. Further, yarn contained on therigid core does not cover the complete core, thereby allowing yarn tosag under the above conditions, exposing holes in the rigid perforatedye core.

After conventional dyeing or setting processes employing perforate metaldye cores it has been diflicult to rapidly dry the yarn packageemploying radio frequency dielectric drying systems owing to theundesirable dielectric properties of the metal core. Additionally,uneven rewinding of the dried yarn package often results from rigid dyecores. Such cores do not respond to changes in the tension of the yarnin the inner portion of the pack age on rewinding.

SUMMARY OF THE INVENTION It is, therefore, a primary object of thisinvention to provide a simplified method with minimum yarn packagedistortion for removing the rigid, imperforate transfer core from awound package of filament or spun yarn and inserting, in lieu thereof, aresilient, foraminous dye core or replacement core in order to permitfree flow of liquid therethrough and through the package duringstabilizing treatment.

It is another object of the invention to provide a replacement core fora yarn package adapted to provide increased capacity for packagemachines for dyeing and/ or setting.

It is an additional object of the invention to provide a replacementcore adapted to control potential yarn sagging problems duringprocessing and short term storage.

The above and other objects are met in a method for transferring apackage of yarn supported by a rigid, imperforate transfer core to aforaminous, resilient dye core of predetermined smaller diametercomprising, in sequence, the steps of inserting the resilient core intothe transfer core and removing the transfer core while preventing axialmovement between the yarn package and resilent core. The elimination ofthe core replacement method by which the dye core is pushed into theyarn package as the transfer core exits, also negates the use of the dyesleeve or sock with its attendant disadvantages. Distortion in the yarnpackage is minmized, since the package merely shrinks about theresilient core as the transfer core is removed. Further, owing to theability of the replacement core to axially compress, the capacity of dyepackage machines can be increased from 30 to 50% over machines filledwith yarn packages with rigid dye cores.

In addition, this axial compression feature permits stacking of yarnpackages with no gaps therebetween, thus overcoming yarn sagging andalso permits yarn to completely cover the stacked cores, furtherpreventing yarn sagging.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages willbecome apparent from the following detailed description of the inventionwhich is to be taken in conjunction with the accompanying drawingsillustrating a preferred embodiment of the invention and in which:

FIG. 1 is an elevational view illustrating the insertion of areplacement core into the transfer core of a yarn package;

FIG. 2 is a top view of a yarn package and a central transfer core;

FIG. 3 is an exploded view, partially in section, of an apparatussuitable for replacing and inserting cores of and into yarn packages andalso illustrating the relative position thereon of a yarn packagecontaining a transfer tube and replacement tube;

FIG. 4 is a fragmentary, vertical sectional view of a yarn packageengaged by the core replacing and inserting apparatus of FIG. 3;

FIG. 5 is a fragmentary, vertical sectional view of the assembly of FIG.4 illustrating the removal of the transfer core from the yarn package;

FIG. 6 is a vertical sectional view of a yarn package contracted about areplacement core; and

FIG. 7 is a top view of the yarn package of FIG. 6.

DESCRIPTION OF PREFERRED EMBODIMENTS Referring now to the drawings and,particularly FIGS. 1 and 2, there is illustrated the first step in thetransfer process. A spun yarn 10 is wound onto a rigid imperforatetransfer core 12 by conventional processes. The process is applicable tovarious types of yarn, including continuous filament yarn. A typicalyarn bulking process is disclosed in U.S. Pat. No. 3,425,110 andillustrated in FIG. 1 of said patent. The conventional bulked yarnpackage produced by such a process varies in bulk level. The bulk levelof the yarn in the outer portion 14 of the package is at the level whichis ultimately desired, while the bulk level of the yarn in the innerportion 16 of the package is below such level. The difference in bulklevel is produced by the transfer core 12 which prevents the innerportion 16 of the yarn package from contracting. The bulked yarnsuitable for the present process, has a strong tendency to contractowing to its highly stretchable nature after it is wound into packageform.

Initially, a foraminous, resilient replacement core is introduced intothe transfer core in concentric alignment therewith. The replacementcore should be of a lesser diameter than the diameter of the transfercore to permit sufiicient expansion of the yarn package 10 to achievethe desired uniform bulk level. This difference in diameter will varywith different types and deniers of yarns.

The replacement 'core is a foraminous, resilient dye core and, mostpreferably, a resilient, spring tube. The replacement core should permitfree flow of liquid therethrough and through the yarn packing duringlater stabilizing treatment. Further, the core should 'be susceptible toaxial compression in order to substantially increase the carryingcapacity of a yarn package dyeing machine. A particularly suitable dyespring tube is disclosed in U.S. Pat. No. 2,670,852 and consists of aspiral spring provided with a sheath formed from a single wire whichextends in the form of a spiral around adjacent turns of the spiralspring, the turns of the spiral wire which extend between any threeturns of the spiral spring being arranged so that they alternate withone another on the intermediate turn of the three turns.

After the replacement core has been coaxially inserted within thetransfer core, suitable means are employed to axially remove thetransfer core while fixedly retaining the yarn package against axialmovement with respect to the replacement core. As illustrated in FIGS. 6and 7, once the transfer core is removed from the yarn package, thepackage contracts about replacement core 18. The amount of contractionof the inner portion of the yarn 1 is controlled by varying thethickness of the transfer tube 12 or by varying the inside diameter ofthe transfer tube 12 in relation to the outside diameter of thereplacement core.

After replacement of the transfer core with the replacement core,.theyarn package may be compressed and thereafter further stabilized byforcing a heated liquid through the package, as will be discussedhereinafter.

A satisfactory assembly for indexing the replacement core properlywithin the transfer core and for removing the transfer core from theyarn package is illustrated in FIGS. 3-5. Turning now to FIG. 3,v theapparatus includes an annular base plate 20 having an annular upraisedshoulder portion or spacing plate 22 for receiving the yarn package 10.A vertical cylindrical mandrel 24 is centrally disposed in base plate20. The mandrel is of smaller diameter than replacement core 18 andserves to retain the replacement core from longitudinal movement duringthe core transfer process.

An annular recessed channel 26 is spaced between shoulder 22 and mandrel24. The channel permits entry of the transfer tube and replacement coreto the proper depth for transfer purposes. The mandrel 24, spacing plate22, and channel 26, provide a fixed base for yarn package 10 therebypreventing longitudinal movement during the core transfer process.

Annular top plate 28 is of greater diameter than the transfer tube 12and is adapted to restrain yarn package 10 against axial movement duringremoval of the transfer tube 12.

The physical removal of transfer tube 12 from yarn package 10 isaccomplished by means of vertically movable clamping assembly 30. Theassembly is adapted to engage the protruding end 13 of transfer tube 12by means of jaw clamp 34 and pull the tube out of the yarn package.

As illustrated in FIGS. 4 and 5, during operation of the transfer corereplacement apparatus, spiral spring replacement coil 18 is insertedover mandrel 24 (in phantom lines). Yarn package 10 is seated on spacingplate 22 and transfer tube 12 is seated in recessed channel 26. Topplate 28 is seated over yarn package 10.

Vertically movable assembly 30 is actuated and engages the protrudingportion 13 of transfer tube 12 by means of locking collar 32 and jawclamps 34. After engagement, locking assembly 30 is withdrawn, therebypulling transfer tube 12 from yarn package 10. To facilitate Withdrawalof the transfer tube, it is preferred to employ a replacement coil whichis shorter than the transfer tube so that the jaw clamps will havesufficient space to engage and remove the transfer core. It is animportant advantage of the invention that as transfer tube 12 iswithdrawn from the yarn package, spiral spring replacement core 18,spaced apart from the transfer tube, undergoes no axial movement. Thus,yarn strands are not displaced during core transfer, a significantadvantage over the prior art. To further prevent axial movement of thereplacement core during removal of the transfer core, a clampingassembly may be concentrically disposed within the jaw clamps to gripthe spring coil during core transfer. This assembly may consist of jawclamps or other conventional gripping devices.

The thus-modified yarn package may be subjected to various finishingoperations such as compressing, dyeing and heat setting. It is knownthat yarn has a tendency to build up and form hard spots at the top andbottom of the yarn package. In order to break up such hard spots in thepackage and achieve a more uniform density, a compressing operation maybe carried out immediately after the core replacement operationemploying the vertically movable assembly to compress the yarn package.

After compression, the yarn package may be stabilized by conventionalwet setting and steam setting means. In practice yarn packages areselectively dyed after compression and/or core replacement inconventional package dyeing machines, wherein a plurality of yarnpackages are spaced on a package carrier. The carrier is lowered into akier or pressure-dyeing chamber and dye liquor is circulated through theyarn packages therein. By employing resilient spring dye cores, thecarrying capacity of the conventional package machines, for example, the

Gaston County package machine, may be increased from 30 to 50%.

After dyeing or stabilizing, it is often desirable to dry the yarnpackages by high speed systems, as dielectric drying systems, ratherthan by conventional mechanical water extractors, such as centrifugalextractors or port dryers. However, metal dye cores do not favorablyrespond to a radio frequency drying field owing, in part, to theirundesirable dielectric properties. Further, it is desirable to minimizethe requirement for metal, particularly stainless steel dye cores, toincrease their lifetime. For the above and other reasons, it ispreferable to replace the resilient, foraminous dye cores, after dyeing,with a plastic support core, and particularly a spline-type plasticspring. The use of resilient plastic cores in yarn packages permit highspeed dielectric drying processes and minimize the requirement for metaldye cores for yarn packages. Further, resilient, plastic cores, andparticularly splined plastic springs facilitate uniform rewinding of theyarn package to winding cores, since such splined springs areparticularly adapted to take up any sag and slack on the inside portionof the yarn package.

The aforesaid plastic cores are inserted into the metal spring supportedyarn packages in the manner described hereinbefore. Such plastic coresare of lesser diameter than the resilient metal dye spring cores and arereadily inserted into the dye spring cores. Suitable gripping means (notshown) are employed to remove the spring core, thereby permitting theyarn to contract about the plastic core.

The following examples are given to further illustrate the nature of theinvention and are not limitative of scope.

EXAMPLE I A spun cotton yarn is formed into a package on a cardboardtakeup tube having an outside diameter of 2.25

' inches and a wall thickness of 0.09 inch.

A spring steel replacement core, 1.94 inches in outside diameter, isplaced over the mandrel of a suitable core replaced apparatus. The yarnpackage is seated over the replacement core. The cardboard tube iswithdrawn from the yarn package by the core replacement apparatus.

The yarn package is thereafter compressed to a 60 to 100% overload byapplying an axial compressive force thereto. The compressed package isthen placed in a package dyeing machine and dyed. The dyed andstabilized yarn package is then pressure extracted and dried in aconventional manner.

EXAMPLE II The yarn package of Example I is processed according to theprocedures of Example I with the exception that a spline type plasticspring core is inserted into the dyed yarn package. The spring steelcore is removed by suitably modified core replacement apparatus. Theyarn package is thereafter dried by a dielectric drying system andrewound onto a take-up cone for further processing.

Further advantages are obtained by the unique process disclosedhereinabove. By replacing the transfer cores with resilient cores, moreuniformity is obtained during yarn dyeing. Individual diiferences inspring tension between resilient cores can be corrected by applyingsufiicient axial pressure to each column of resilient cores to producethe same volumetric density in the yarn packages. With conventionalrigid dye cores such density differences cannot be so compensated,thereby creating problems with uneven bulking or shrinkage of filamentor spun yarns.

The above invention is not to be limited except as set forth in thefollowing claims.

I claim:

1. A method for transferring a package of yarn supported by a rigidimperforate transfer core to a foraminous, resilient dye core ofpredetermined smaller diameter comprising, in sequence, the steps of:

(a) inserting the resilient core into the transfer core;

and

(b) removing the transfer core while preventing axial movement betweenthe yarn package and resilient core.

2. The method of claim 1 in which the replacement core is a spiralspring dye tube.

3. The method of claim 2 including the steps of dyeing the spring coresupported yarn package and thereafter replacing said spring core with aresilient plastic core of smaller diameter than said spring core, saidplastic coresupported yarn package being adapted for dielectric drymg.

4. The method of claim 3 in which the plastic core is a splined spring"core.

5. A method for processing a package of yarn supported by a rigidimperforate transfer core comprising:

(a) replacing said transfer core with a resilient foraminous dye core,according to claim 1; and

(b) dyeing said yarn package.

6. The method of claim 5 including the step of replacing the dye corewith a plastic support core capable of sustaining dielectric drying.

7. The method of claim 6 wherein the plastic support core is a splinedspring core adapted to facilitate uniform rewinding of said yarnpackage.

References Cited UNITED STATES PATENTS 254,386 2/1882 'Rusch 68189 XFOREIGN PATENTS 482,817 4/1938 Great Britain 8-l54 WILLIAM I. PRICE,Primary Examiner US. Cl. X.R. 68198

